Charging System. Alternator Rotor/Starter Clutch Installation

Alternator Rotor/Starter Clutch Installation

• Apply a non-permanent locking agent to the threads of the
starter clutch Allen bolts, and tighten them to the specified
torque in assembling the starter clutch onto the alternator
rotor.

Torque -Starter Clutch Allen Bolts: 34 N-m (3.5 kgf-m, 25 ft-lb)

OBe careful that the rollers do not drop out of the starter clutch during assembly.

• Using a high flash-point solvent, clean off any oil or dirt that may be on the crankshaft taper [A] and rotor tapered hole [B].

• Fit the woodruff key securely in the slot [C] in the crank­shaft before installing the rotor assembly on the crank­shaft.

• Tighten the rotor bolt while holding the rotor steady with
the flywheel holder, and turn the rotor bolt counterclock­
wise to install it.

Torque -Alternator Rotor Bolt: 69 N-m (7.0 kgf-m, 51 ft-lb) Special Tool - Flywheel Holder: 57001-1410

• Apply silicone sealant to the area [A] where the mating
surface ends of the crankcase touch the alternator cover
gasket.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

• Apply silicone sealant around the circumference of the
wiring grommets before setting it in the notch in the al­
ternator cover.

Sealant - Kawasaki Bond (Liquid Gasket): 92104-1063

• Check that knock pins [B] are in place on the crankcase.

• Tighten the alternator cover bolts.

Torque-Alternator Cover Bolts: 11 N-m (1.1 kgf-m, 95 in-lb)

• Install the other removed parts.

• Check the engine oil level, and add if necessary (see En­gine Oil Level Inspection in the Engine Lubrication Sys­tem chapter).

Alternator Stator Removal

NOTE

О To keep the loss of engine oil to a minimum, set the motorcycle vertically.

• Remove the alternator cover (see Alternator Rotor and
Starter Clutch Removal).